I figured I should probably start a built thread. Additional input and advice can only help, right? If anything it should help keep me on a better schedule so that I can get back out on the trails sooner rather than later. I've been traveling like crazy, but, my goal is to have the tear down finished by April .

A little background...

My uncle let me drive his 1995 LWB (which is now my current DD) when I was 12. By the time I got my license he was still driving his classic daily which put me on a hunt for my own. A few months later I came across this 1990 RRC in a neighboring town in NY and bought it.

The previous owner was kind enough to drive it about 25 miles back to my house where it blew a head gasket in the middle of the driveway. My father and I turned it into a father-son project and rebuilt the engine in the garage over the next few months.

Over the years of my ownership I have pushed it hard both on the road and on the trails. It's bounced off trees, teetered on two and three tires, towed boats, cars, and more. It's been up and down the east coast, rescued my parents and friends numerous times and never let me down.

After 23 years in NY and two exploring the coast, the body has finally had enough. And now, I finally have the chance to tear it down to the bare essentials and replace the rotted metal.

So far? I'm about 12 inconsistent hours involved. Armed with a haynes manual and harbor freight down the road, the project should be pretty straight forward. Cut out the old, replace with new, then paint it because it's life depends on it.

Current:

Rot has destroyed everything... Literally everything... The more I tear up the more I know i'm going to replace. 25 years of rust also knows how to put up one hell of a fight. I started from the tailgate and am working my way forward. Part 1 will get me to the front seats.

rear-cross member - toast
trunk - toast
body that holds the trunk in place - toast
the floor where those sitting in the back would put their feet - toast
rear wheel wells - toast
passenger-front-seat-floor -- not good, not great
Drivers seat - repaired already (I had to sit somewhere)
firewall - crusty
front wheel wells - crunchy and separated from the rest of the body

But, the frame is solid, the drive-train is mint and I have kickass rock sliders. This project rocks.

I am doing a very similar thing with my brother and his RRC. It is just as bad. YRM is awesome stuff but it will cost more than the truck is worth for all the panels you will need. The cheap easy option is buy a west coast truck with a blown motor, and ship it over. As this is a learning experience and bonding project for my brother and I, we bit the bullet, bought the yrm panels from Urban, with full knowledge we will never get a return on our investment.

Take it apart very systematically. Once we took out the floor, the rear end lost all structural integrity and the rear doors would not open until we jacked up the body in preparation to weld the rear crossmember in.

I am glad to hear someone else is daft enough to save one of these too
Best of luck with the project!

You can get most of those panels out of the UK. Betting if you gave Eric part numbers he could get it all for you. The older I get the more I appreciate the time lost fabricating things that can be bought.Body - YRM Metal Solutions

I've used panels from both YRM & Paddocks… both are nice. My first RRC was in a similar state well not quite so bad. I'd guess your sills are toast too. My plan, which did not happen, was to replace with 2x4 box steel. Here's a write I was going by… 12th October 2008 011

I would also guess most of your body mounts are toast too. The ones on my bulkhead were gone completely & the fronts were just hanging on along with a lot of cancer in the headlight buckets.

I've used panels from both YRM & Paddocks… both are nice. My first RRC was in a similar state well not quite so bad. I'd guess your sills are toast too. My plan, which did not happen, was to replace with 2x4 box steel. Here's a write I was going by… 12th October 2008 011

I would also guess most of your body mounts are toast too. The ones on my bulkhead were gone completely & the fronts were just hanging on along with a lot of cancer in the headlight buckets.

The driver side sill actually fell off the truck, back in 2012, due to the rot. They were quickly replaced by M4 Fabrications and are now dual purpose rock sliders. They're welded directly to the frame and wrap up into the body.

If you have the time, tools, and patience and really want to preserve the truck---it can be done.
I think I'd go the route of finding a good donor, making up some templates, and cutting out the needed panels to repair.

StrangeRover/Frank did a nice cargo floor repair of his 89 RRC and he made the floor removeable I think.
Its written up on ROVERS club forum.

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Just a few miles from 4x4 access!

Good to see that you are starting this process!
I would be the same with my RRC! It will require time and patience. But it will be good to know that it has been your truck all along, and not some donor vehicle.

Let me know if you need any help. Although my welding skills are extremely horrible.

Land Rover Loyality after 20 plus years of Loyal Service and cherished memories...

I am truly looking forward to following this thread. If more people thought this way we would not have such a disposable society....a time when Rigs were able to be rebuilt and improved and reborn.......Land Rover....